Dual-Sided Centrifugal Fan

ABSTRACT

A dual-sided impeller for a centrifugal blower assembly is provided. The dual-sided impeller comprises a plurality of fan ribs defined in a single continuous metal sheet and extending from a hub toward a circumference of the impeller. Each of the plurality of fan ribs has first and second vanes, wherein the first and second vanes extend in opposing directions relative to a plate region of the impeller. The first and second vanes can comprise one or more of a forward-curved vane, a backward-curved vane, a forward-inclined vane, a backward-inclined vane, and a radial vane. The centrifugal blower assembly comprises a blower housing, wherein the dual-sided impeller is disposed within the blower housing. The dual-sided impeller is continuous and is stamped and/or pressed from a single sheet of metal, such as one or more of a sheet of steel, stainless steel, and aluminum.

REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. Provisional Application Ser. No. 61/919,308 which was filed Dec. 20, 2013, entitled “DUAL-SIDED FAN BLADE”, the entirety of which is hereby incorporated by reference as if fully set forth herein.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to air movement systems, and more specifically to a continuous dual-sided centrifugal impeller and blower system.

BACKGROUND OF THE DISCLOSURE

A centrifugal fan is a mechanical device for moving air or other gases, and is often used in heating ventilation, and air conditioning (HVAC) systems. Conventional centrifugal fans are also commonly referred to as “blowers” or “squirrel cage fans”, as the configuration of a typical centrifugal fan often resembles an exercise wheel for a hamster or rodent.

Centrifugal fans increase the velocity of a stream of gas (e.g., air) via a rotation of impellers that are coupled to a power source, such as a motor. Kinetic energy associated with the rotation of the impellers increases a pressure of the stream of gas which, in turn, can counter resistance caused by ducts, conduits, dampers, and other HVAC components. Centrifugal fans typically rotate about an axis and accelerate the air or gas radially, therein changing the direction of the airflow (e.g., typically changing the direction by 90 degrees).

Conventional centrifugal fans are comprised of numerous components that are assembled to form a final fan assembly. For example, a conventional centrifugal fan has a plurality of individual vanes that are assembled between two or more plates, whereby the two or more plates subsequently retain the plurality of vanes in place. Such vanes are often welded, crimped, or otherwise mechanically coupled to the plates during the manufacturing process, thus leading to significant manufacturing costs and time for assembly.

SUMMARY OF THE DISCLOSURE

The present disclosure overcomes various limitations of the prior art by providing a continuous centrifugal fan impeller, whereby various manufacturing costs and complexities are ameliorated. The following presents a simplified summary of the disclosure in order to provide a basic understanding of some aspects of the disclosure. This summary is not an extensive overview of the disclosure. It is intended to neither identify key or critical elements of the disclosure nor delineate the scope of the disclosure. Its purpose is to present some concepts of the disclosure in a simplified form as a prelude to the more detailed description that is presented later.

The present disclosure is directed generally toward a system and apparatus for moving a fluid. In particular, the present disclosure relates to centrifugal blower assemblies and a dual-sided centrifugal impeller configured to be disposed within a blower housing.

In accordance with one aspect of the disclosure, a centrifugal blower assembly is provided, wherein the centrifugal blower assembly comprises a blower housing, and wherein a shaft is rotatably coupled to the blower housing along an axis. A centrifugal impeller is further disposed within the blower housing. The centrifugal impeller, for example, comprises a hub coupled to the shaft along the axis. Accordingly, the centrifugal impeller is rotatably coupled to the blower housing and operable to rotate therein upon a rotational input provided to the shaft.

According to one exemplary aspect, the centrifugal impeller further comprises a plurality of fan ribs extending from the hub toward a circumference of the centrifugal impeller. In accordance with the present disclosure, the hub and plurality of fan ribs are defined in a continuous material (e.g., a singular, contiguous, and unitary material). The continuous material, in one example, comprises a single continuous sheet of material, such as a metal sheet, wherein various acts of stamping and pressing can be performed on the single sheet of material to form the centrifugal impeller.

By forming the centrifugal impeller in a continuous metal sheet in a generally uninterrupted manner (e.g., without welds or other fastening of multiple components), the costs associated with manufacturing and assembly of the centrifugal blower assembly are decreased while various operating efficiencies and air flow characteristics associated with the centrifugal blower assembly are advantageously achieved by the present disclosure.

Each of the plurality of fan ribs, for example, comprises a plate region, a first vane and a second vane. The plate region, for example, is generally planar and oriented generally perpendicular to the axis, wherein the first vane and second vane extend from the plate region in respective opposing directions. For example, the first vane and second vane extend generally parallel to the axis from the plate. The first vane and second vane, for example, are respectively one of forward-curved, backward-curved, forward-inclined, backward-inclined, and radial. For example, the first vane can comprise a forward-curved vane, while the second vane can comprise a forward-inclined vane. In another example, each of the first vane and second vane comprise radial vanes. In still another example, both of the first vane and second vane are one of forward-curved, backward-curved, forward-inclined, backward-inclined, and radial. In yet another example, any combination of the above first and second vanes is contemplated.

The first and second vanes of the centrifugal impeller, for example, are configured to draw a fluid (e.g., air or other gases, liquids, or a combination of gas and liquid) through opposing sides of the blowing housing upon a rotation of the impeller within the blower housing. As such, each side of the first and second vanes of the centrifugal impeller can be inclined or curved to suit the need for withdrawing and/or expelling fluids from the centrifugal blower assembly.

In another example, a strengthener is formed in the continuous material, wherein the strengthener is associated with at least one or more of the plurality of fan ribs, and wherein the strengthener additionally provides rigidity to the plurality of fan ribs. The strengthener, for example, can comprise a ribbed structure formed in the continuous metal sheet.

According to yet another example, the blower housing comprises a first inlet associated with a first side of the impeller, a second inlet associated with a second side of the impeller, and an exhaust. The first inlet and second inlet, for example, comprise axial inlets defined in opposing sides of the blower housing, and wherein the exhaust is positioned radially with respect to the axis. Thus, the centrifugal blower assembly of the present disclosure can be configured to concurrently draw fluids from two opposing sides of the blower housing and exhaust the fluid radially in an efficient manner.

Thus, to the accomplishment of the foregoing and related ends, the disclosure comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the disclosure. These embodiments are indicative, however, of a few of the various ways in which the principles of the disclosure may be employed. Other objects, advantages and novel features of the disclosure will become apparent from the following detailed description of the disclosure when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-sectional side view of a centrifugal blower assembly according to one example.

FIG. 2 illustrates a cross-sectional plan view of a centrifugal blower assembly according to another example.

FIG. 3 illustrates a perspective view of an exemplary dual-sided centrifugal impeller of the present disclosure.

FIG. 4 illustrates another perspective view of an exemplary dual-sided centrifugal impeller of the present disclosure.

FIG. 5 illustrates yet another perspective view of an exemplary dual-sided centrifugal impeller of the present disclosure.

FIGS. 6A-6C illustrate respective plan, perspective, and side views of another exemplary dual-sided centrifugal impeller of the present disclosure.

FIGS. 7A-7C illustrate respective plan, perspective, and side views of yet another exemplary dual-sided centrifugal impeller of the present disclosure.

FIG. 8 illustrates still another perspective view of an exemplary dual-sided centrifugal impeller of the present disclosure, as well as a single sheet of contiguous material which forms the dual-sided centrifugal impeller.

FIG. 9 illustrates an exemplary methodology for forming a centrifugal impeller.

DETAILED DESCRIPTION

The present disclosure provides a system, apparatus, and method for moving a fluid such as air or other gases or liquids via a centrifugal blower assembly having a centrifugal impeller disposed within a blower housing. In particular, the centrifugal impeller is comprised of a continuous (e.g., uninterrupted or singular) material, wherein various manufacturing and operational efficiencies are attained. Further, the centrifugal impeller is configured to draw a fluid (e.g., air or other gases, liquids, or a combination of gas and liquid) through opposing sides of the blowing housing upon a rotation of the impeller within the blower housing.

Accordingly, the following description is made with reference to the drawings, in which like reference numerals are generally utilized to refer to like elements throughout, and wherein the various structures are not necessarily drawn to scale. In the following description, for purposes of explanation, numerous specific details are set forth in order to facilitate understanding. It may be evident, however, to one skilled in the art, that one or more aspects described herein may be practiced with a lesser degree of these specific details. In other instances, known structures and devices are shown in block diagram form to facilitate understanding.

Referring initially to FIGS. 1 and 2, a centrifugal blower assembly 100 is provided in accordance with one exemplary aspect of the present disclosure. The centrifugal blower assembly 100, for example, can be utilized in withdrawing and expelling exhaust gases from a furnace or other device. Alternatively, the centrifugal blower assembly 100 can be incorporated into an HVAC system or other system wherein fluids such as air or other gases and/or liquids are moved.

The centrifugal blower assembly 100 of FIGS. 1 and 2, for example, comprises a blower housing 102, wherein a shaft 104 is rotatably coupled to the blower housing along an axis 106. A centrifugal impeller 108 is disposed within the blower housing, wherein the centrifugal impeller, in one example, comprises a hub 110 operably coupled to the shaft 104 along the axis 106. The hub 110 can be coupled to the shaft 104, for example, by a set screw or other fastener (not shown), as will be understood by one of ordinary skill. The centrifugal impeller 108 in the present example is thus rotationally driven via a drive means 112 coupled to the shaft 104 along the axis 106. The drive means 112 of FIG. 1, for example, rotationally drives the shaft 104 and can comprise one or more of a motor, belt, pulley, gear, direct-drive mechanism, indirect-drive mechanism, or any other drive means that would be evident to one of ordinary skill. Accordingly, the centrifugal impeller 108 is operable to rotate within the blower housing 102 upon any rotational input provided to the shaft 104.

In one exemplary aspect, the blower housing 102 comprises a first inlet 118A associated with the first side 116A of the housing and impeller 108, and a second inlet 118B associated with the second side 116B of the housing and impeller. Upon rotation (e.g., illustrated by arrow 118 in FIG. 2) of the centrifugal impeller 108 within the blower housing 102, the centrifugal blower assembly 100 is configured to draw fluid through the intake regions 114A, 114B (e.g., illustrated by arrows 120 in FIG. 1), and to exhaust the gases through an exhaust 122 (e.g., illustrated by arrows 124 in FIG. 2), wherein the exhaust is positioned radially with respect to the axis 106.

Thus, the centrifugal blower assembly 100 of the present disclosure can be configured to concurrently draw fluids from opposing sides (e.g., the first and second sides 116A, 116B) of the blower housing 102 and exhaust the fluid radially in an efficient manner. It should be noted that while the blower assembly 100 is described with respect to drawing and exhausting gases, the blower assembly can be implemented with the conveyance of any fluid such as a gas, liquid, or any gas/liquid/solid combination, and all such implementations are contemplated as falling within the scope of the present disclosure. It should also be noted that the direction of rotation 118 of the centrifugal impeller 108 can vary based on a design of the centrifugal impeller.

In accordance with the present disclosure, the centrifugal impeller 108 is further illustrated in various examples shown in FIGS. 3-8. It should be noted that the examples illustrated in FIGS. 3-8 are not intended to limit the disclosure, but rather, to show a variety of example configurations of the centrifugal impeller 108.

According to one exemplary aspect, the centrifugal impeller 108 further comprises a plurality of fan ribs 126 extending from the hub 104 toward a circumference 128 (e.g., illustrated in FIGS. 2 and 8) of the centrifugal impeller. The number of fan ribs 126 can be chosen based on desired flow characteristics and manufacturing capabilities.

In accordance with the present disclosure, the hub 104 and plurality of fan ribs 126, as illustrated in FIG. 8, are defined in a continuous material 130 (e.g., a singular, contiguous, and unitary material). The continuous material 130, in one example, comprises a metal sheet 132 (e.g., shown in phantom in FIG. 8 prior to formation of the centrifugal impeller 108), wherein various acts of stamping and pressing can be performed on the metal sheet to form the centrifugal impeller 108. By being defined in the metal sheet 132, for example, the hub 104 and plurality of fan ribs 126 are unitary and continuous with one another. The metal sheet 132, for example, can be comprised of one or more of steel, stainless steel, and aluminum.

By forming the centrifugal impeller 108 in a continuous material 130 in a generally uninterrupted manner (e.g., without welds or other fastening of multiple components), the costs associated with manufacturing and assembly of the centrifugal blower assembly 100 of FIGS. 1 and 2 are decreased while various operating efficiencies and air flow characteristics associated with the centrifugal blower assembly are advantageously achieved by the present disclosure.

Each of the plurality of fan ribs 126, for example, comprises a plate region 134, a first vane 136 and a second vane 138, as illustrated in FIGS. 3-8. The plate region 134, for example, is generally planar and oriented generally perpendicular to the axis 106 of FIG. 1, wherein the first vane 136 and second vane 138 of FIGS. 3-8 extend from the plate region in respective opposing directions. For example, the first vane 136 and second vane 138 extend from the plate region 134 generally parallel to the axis 106 (e.g., extending approximately 90 degrees from the plate region). It should be noted, however, that the first vane 136 and second vane 138 can extend from the plate region 134 at various angles with respect to the plate region, according to the desired characteristics of the centrifugal impeller 108.

Both the first vane 136 and second vane 138 of the centrifugal impellers 108 of FIGS. 3-8, for example, are respectively one of forward-curved, backward-curved, forward-inclined, backward-inclined, and radial. For example, the first vane 136 and second vane 138 of the centrifugal impeller 108 of FIG. 3 both comprise a forward-curved vane 140. Alternatively, in another example, although not shown, the first vane 136 can comprise the forward-curved vane 140, such as illustrated in FIG. 3, while the second vane 138 can comprise a forward-inclined vane 142, such as illustrated in FIG. 6A. In another example, each of the first vane 136 and second vane 138 can comprise radial vanes as illustrated in FIGS. 7A-7C. In yet another example, any combination of the above first vane 136 and second vane 138 is contemplated, and all such combinations are contemplated as falling within the scope of the present disclosure.

The first vane 136 and second vane 138 of the centrifugal impeller 108 of any of FIGS. 3-8, for example, are thus configured to draw a fluid (e.g., air or other gases, liquids, or a combination of gas and liquid) through opposing sides (e.g., the first and second sides 116A, 116B) of the blowing housing 102 of FIG. 1 upon the rotation of the centrifugal impeller 108 within the blower housing. As such, each side of the first van 136 and second vane 138 of the centrifugal impeller 108 can be inclined or curved to suit the need for withdrawing and/or expelling fluids from the centrifugal blower assembly 100.

In another example, a strengthener 144, as illustrated in FIGS. 3-8, for example, is formed in the continuous material 130, wherein the strengthener is associated with at least one or more of the plurality of fan ribs 126, and wherein the strengthener additionally provides rigidity to the plurality of fan ribs. The strengthener 144, for example, can comprise a ribbed structure formed in the continuous material 130 via a pressing or stamping operation.

Thus, the continuous material 130 can comprise a single sheet of material such as the metal sheet 132 of FIG. 8 that is stamped to produce the dual-sided impeller vanes discussed above. The present disclosure contemplates various combinations of dual-sided impeller vanes, such as various combinations of backward inclined, forward inclined, backward curved, forward curved, and radial directed impeller vanes. Additionally, each side of the dual-sided impeller vanes can be inclined or curved to suit the need for withdrawing and/or expelling fluids from the blower assembly. By providing the centrifugal impeller 108 comprised of dual-sided impeller vanes formed from a single sheet of contiguous metal, the cost of the blower is decreased while various efficiencies of the blower assembly and air flow characteristics are achieved.

According to another aspect of the present disclosure, a method 200 for forming a dual-sided impeller is provided in FIG. 9. The method 200 comprises providing a single sheet of material having a plane associated therewith in act 202. In act 204, the single sheet of material is stamped, therein forming a blank, wherein the blank generally defines a plurality of fan ribs extending from a hub. In act 206, the blank is pressed, therein forming a first vane and a second vane associated with each of the plurality of fan ribs, wherein the first vane and second vane extend in opposing directions relative to the plane. Pressing the blank in act 206, for example, comprises a first press operation and a second press operation, wherein the first press operation generally defines the first vane, and wherein the second press operation generally defines the second vane.

In one example, the first press operation and second press operation of act 206 are performed serially. In another example, the first press operation and second press operation of act 206 are performed concurrent to one another. in yet another example, the stamping operation of act 204 and first and second press operations of act 206 are performed concurrent to one another.

Although the present embodiments and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

While the method(s) provided herein is illustrated and described below as a series of acts or events, it will be appreciated that the illustrated ordering of such acts or events are not to be interpreted in a limiting sense. For example, some acts may occur in different orders and/or concurrently with other acts or events apart from those illustrated and/or described herein. In addition, not all illustrated acts may be required to implement one or more aspects or embodiments of the description herein. Further, one or more of the acts depicted herein may be carried out in one or more separate acts and/or phases.

It will be appreciated that while reference is made throughout this document to exemplary structures in discussing aspects of methodologies described herein, that those methodologies are not to be limited by the corresponding structures presented. Rather, the methodologies (and structures) are to be considered independent of one another and able to stand alone and be practiced without regard to any of the particular aspects depicted in the Figs.

Also, equivalent alterations and/or modifications may occur to those skilled in the art based upon a reading and/or understanding of the specification and annexed drawings. The disclosure herein includes all such modifications and alterations and is generally not intended to be limited thereby. In addition, while a particular feature or aspect may have been disclosed with respect to only one of several implementations, such feature or aspect may be combined with one or more other features and/or aspects of other implementations as may be desired. Furthermore, to the extent that the terms “includes”, “having”, “has”, “with”, and/or variants thereof are used herein, such terms are intended to be inclusive in meaning—like “comprising.” Also, “exemplary” is merely meant to mean an example, rather than the best. It is also to be appreciated that features, layers and/or elements depicted herein are illustrated with particular dimensions and/or orientations relative to one another for purposes of simplicity and ease of understanding, and that the actual dimensions and/or orientations may differ substantially from that illustrated herein. 

What is claimed is:
 1. A centrifugal impeller, comprising: a hub, wherein a center of the hub defines an axis about which the hub is configured to rotate; and a plurality of fan ribs extending from the hub toward a circumference of the centrifugal impeller, wherein the hub and plurality of fan ribs are defined in a continuous metal sheet, wherein each of the plurality of fan ribs comprises a plate region, a first vane and a second vane, wherein the plate region is generally planar and oriented generally perpendicular to the axis, and wherein the first vane and second vane extend from the plate region in respective opposing directions, and wherein the first vane and second vane are respectively one of forward-curved, backward-curved, forward-inclined, backward-inclined, and radial.
 2. The centrifugal impeller of claim 1, wherein both of the first vane and second vane are one of forward-curved, backward-curved, forward-inclined, backward-inclined, and radial.
 3. The centrifugal impeller of claim 1, wherein the first vane and second vane extend generally parallel to the axis.
 4. The centrifugal impeller of claim 1, further comprising a strengthener formed in the continuous metal sheet, wherein the strengthener is associated with one or more of the plurality of fan ribs, and wherein the strengthener provides additional rigidity to the plurality of fan ribs.
 5. The centrifugal impeller of claim 4, wherein the strengthener comprises a ribbed structure formed in the continuous metal sheet.
 6. The centrifugal impeller of claim 1, wherein the continuous metal sheet comprises an uninterrupted and contiguous sheet of metal.
 7. The centrifugal impeller of claim 1, wherein the hub and plurality of fan ribs are formed by one or more of a stamping operation and a pressing operation.
 8. The centrifugal impeller of claim 1, wherein the hub and plurality of fan ribs are unitary and continuous with one another.
 9. A centrifugal blower assembly, comprising: a blower housing; a shaft rotatably coupled to the blower housing along an axis; and a centrifugal impeller disposed within the blower housing, wherein the impeller comprises: a hub coupled to the shaft along the axis; and a plurality of fan ribs extending from the hub toward a circumference of the centrifugal impeller, wherein the hub and plurality of fan ribs are defined in a continuous metal sheet, wherein each of the plurality of fan ribs comprises a plate region, a first vane and a second vane, wherein the plate region is generally planar and oriented generally perpendicular to the axis, and wherein the first vane and second vane extend from the plate region in respective opposing directions, and wherein the first vane and second vane are respectively one of forward-curved, backward-curved, forward-inclined, backward-inclined, and radial.
 10. The centrifugal blower assembly of claim 9, wherein both of the first vane and second vane are one of forward-curved, backward-curved, forward-inclined, backward-inclined, and radial.
 11. The centrifugal blower assembly of claim 9, wherein the first vane and second vane extend generally parallel to the axis.
 12. The centrifugal blower assembly of claim 9, further comprising a strengthener formed in the continuous metal sheet, wherein the strengthener is associated with at least one or more of the plurality of fan ribs, and wherein the strengthener provides additional rigidity to the plurality of fan ribs.
 13. The centrifugal blower assembly of claim 12, wherein the strengthener comprises a ribbed structure formed in the continuous metal sheet.
 14. The centrifugal blower assembly of claim 9, wherein the continuous metal sheet comprises an uninterrupted and contiguous sheet of metal.
 15. The centrifugal blower assembly of claim 14, wherein the hub and plurality of fan ribs are formed by one or more of a stamping operation and a pressing operation.
 16. The centrifugal blower assembly of claim 14, wherein the continuous metal sheet is comprised of one or more of steel, stainless steel, and aluminum.
 17. The centrifugal blower assembly of claim 14, wherein the hub and plurality of fan ribs are unitary and continuous with one another.
 18. The centrifugal blower assembly of claim 9, wherein the blower housing comprises a first inlet associated with a first side of the impeller, a second inlet associated with a second side of the impeller, and an exhaust.
 19. The centrifugal blower assembly of claim 18, wherein the first inlet and second inlet comprise axial inlets defined in opposing sides of the blower housing.
 20. The centrifugal blower assembly of claim 18, wherein the exhaust is positioned radially with respect to the axis. 